Bendable/twistable rolling conveyor guide

ABSTRACT

Readily bendable and twistable rolling conveyor guides are provided. The guides include axle-positioning members that slidably engage channels of a structural support member. A plurality of axles carrying rotatable elements and spacers are disposed between the axle-positioning members. Certain embodiments include notches in the axle-positioning members. Certain other embodiments include unique cross-sections at the exterior of the channels. Advantageously, the assembled guides may be bent without causing distortion of the channels or interference between the axle-positioning members and the channels. In certain other embodiments, the support structures of the guides are constructed of flexible materials. The guides are thus readily twistable about longitudinal axes thereof.

RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No. 10/789,629, filed on Feb. 27, 2004, now U.S. Pat. No. 6,991,086, which is a continuation-in-part of application Ser. No. 10/366,592, filed on Feb. 11, 2003, now abandoned, which is a continuation of application Ser. No. 09/706,460, filed on Nov. 3, 2000, now U.S. Pat. No. 6,516,933. The entire contents of these applications are hereby expressly incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to guides for installation along the sides of a container-transporting conveyor system. More specifically, the present bendable/twistable rolling conveyor guide is adapted for installation along straight, curved and/or twisting sections of a conveyor system.

2. Description of the Related Art

Guides mounted on opposite sides of conveying systems are used in a variety of places in industrial installations. For example, they are used for combining (channeling a wide procession of conveyed articles in a disorderly array into a single file), forcing articles around bends in the conveying system, or simply preventing articles from falling off the side of the conveyor. Generally, there is at least one guide mounted on each side of the conveyor.

Guides may either be fixed or rolling, depending upon the nature of the guide surface that contacts the conveyed articles. Fixed guides provide a smooth surface for articles to contact, while rolling guides provide rotatable elements mounted upon axles. Guides of both types provide a low friction guiding surface for a large variety of individual containers including glass, metal, plastic and paperboard, and packages like cardboard boxes, and plastic wrapped bundles or trays. Excess friction in any of these applications can cause line stoppage, package jamming and possible damage, product spillage or skewed orientation.

In powered conveyor applications especially, fixed guides generally provide too much friction to be useful, especially when a container or package must be guided around a turn or through a transfer from one conveyor to another. Rolling guides are an excellent solution to these problems. In some curved sections of conveyors, there is only a rolling guide on one side of the conveyor, with a fixed guide on the other side. Where only one rolling guide is used, the rolling guide is usually mounted on the outside, or larger radius, of the curve.

Rolling guides are often constructed in a similar manner. A rolling member is positioned on a shaft or axle and contacts the product/package surface. Sizes of rolling members, and heights of rolling guides, vary. Guides can be from one inch with one member to ten inches with fifteen-plus members. Rolling members can interlock (nest) or stand adjacent. A dense interlocked pattern is generally preferred, because the interlocking members minimize gaps that tend to catch passing articles. The axles are in turn connected to a structural supporting member by means of an axle-positioning plastic cap. Aluminum extrusions, bars of steel or aluminum and formed sections of sheet metal are the most common materials for the supporting member.

For economic reasons, guides are generally manufactured in standard lengths. However, applications for guides often require unique bead lengths. Therefore, either each length must be amenable to being cut, bent and/or twisted by the purchaser to conform to each application, or the purchaser must special order the specific lengths and radii of guides needed, which is typically a more expensive option.

Examples of rolling guides are shown in U.S. Pat. Nos. 3,934,706, 4,962,843 and 5,143,200, and VALU GUIDE Model #684. Each of these guides generally comprises an upper and a lower frame member that are adapted to be mounted alongside and parallel to the conveyor. U.S. Pat. No. 4,962,843 comprises a plurality of vertically stacked frame members. A plurality of axles are disposed between the frame members, usually with the longitudinal axis of each axle oriented perpendicularly to the conveying surface. Rotatably attached to the axles are beads, which are generally spherical, or rollers, which are generally cylindrical with protruding flanges that are either round or polygonal.

This guide configuration is particularly useful for combining, where each guide is straight. However, none of these guides are easily bent after they have been assembled. Further, none of these guides is capable of being twisted. Bending or twisting these guides often results in radical deformation of the supporting structure and even failure. Therefore, none of these guides are well suited for use in curved or twisting sections of a conveying system unless they are custom manufactured to meet a particular customer's need.

Two examples of guides that are more easily bent by the purchaser are the Marbett Model # 580 and 581, and the System Plast device. Each length of these guides comprises multiple short sections of frame members that are all flexibly attached to one another by means of plastic hinges. The back side of each section contains a channel that is adapted to be slidably attached to a bent mounting strip. These designs have some major drawbacks, however. First, the minimum bending radii are rather high (approximately 13″ for an internal curve, and 15″ for an external curve for the Marbett, and approximately 18″ for an internal curve, and 24″ for an external curve for the System Plast). A plant layout requiring tighter radii would not be able to use these guides. Second, because the device only bends between sections, and each section contains four axles, it does not provide an entirely smooth curve. The transition points between sections have a tendency to catch passing articles on the conveyor, leading to jamming. Third, neither of these guides is capable of being twisted.

The design of all of the above-mentioned guides also makes them more expensive to manufacture. The axles must first be inserted into an axle-positioning member. After the rotatable elements have been installed, every single axle must be lined up properly before the other axle-positioning member can be secured to the other end of the axles. This is a very tedious process that is difficult to automate.

A guide that is easily and cheaply manufactured, easily bent and/or twisted by the purchaser, is capable of being bent to small radii, and that doesn't have a tendency to cause conveyed articles to jam would be of great benefit in any industry that uses conveyors.

SUMMARY OF THE INVENTION

The present bendable/twistable rolling conveyor guide has several features, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this conveyor guide as expressed by the claims that follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of the Preferred Embodiments,” one will understand how the features of this conveyor guide provide advantages, which include ease of assembly and ability to be bent and twisted by the purchaser.

The present bendable/twistable rolling conveyor guide is easy to bend and twist, and is thus readily adaptable for use in any conveyor layout. In one embodiment, the bendable/twistable rolling conveyor guide includes any number of axles disposed between a pair of chain-like axle-positioning members. The axles serve as mounting points for rotatable elements such as rollers or beads. The axles and/or spacers may be molded integrally with the axle-positioning members. The axle-positioning members slidably engage two channels in a structural support member. The axle-positioning members are rigid but readily bendable and twistable. Evenly spaced notches cut in the edges of the axle-positioning member contribute to the ready bendability and twistability of the axle-positioning members. The shape of the notches ensures that the axle-positioning members do not interfere with the interior walls of the channels when the entire assembly is bent or twisted. In one embodiment, outer surfaces of the structural support member are shaped so as to mate with surfaces of a bending tool. Inter-engagement of the structural support member with the bending tool minimizes distortion of the structural support member during the bending operation. The structural support member is readily bent to theoretical radii as small as 5″. When constructed of a twistable material, the structural support member is readily twisted by hand to follow twisting sections of conveyor systems.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present bendable/twistable rolling conveyor guide, illustrating its features, will now be discussed in detail. These embodiments depict the novel and non-obvious conveyor guide shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts:

FIG. 1 is a perspective view of a preferred embodiment of the present bendable/twistable rolling conveyor guide;

FIG. 2 is an exploded perspective view of the conveyor guide of FIG. 1;

FIG. 3 is an exploded perspective view of another preferred embodiment of the present bendable/twistable rolling conveyor guide, illustrating another preferred bead and spacer arrangement;

FIGS. 4A–4D are side, front, side detail and rear views, respectively, of the channel member of the conveyor guide of FIG. 1;

FIG. 5A depicts front, side and top views of a preferred embodiment of the axle-positioning member of the present bendable/twistable rolling conveyor guide;

FIG. 5B depicts front, side and top views of another preferred embodiment of the axle-positioning member of the present bendable/twistable rolling conveyor guide;

FIG. 6A depicts front, side and top views of another preferred embodiment of the axle-positioning member of the present bendable/twistable rolling conveyor guide;

FIG. 6B depicts front, side and top views of another preferred embodiment of the axle-positioning member of the present bendable/twistable rolling conveyor guide;

FIGS. 7A–7C are top detail views of preferred embodiments of the axle-positioning member of the present bendable/twistable rolling conveyor guide;

FIG. 8 is a perspective view of a preferred apparatus for bending the present bendable/twistable rolling conveyor guide;

FIG. 9 is a side view of the bending apparatus of FIG. 8;

FIG. 10 is a perspective view of another preferred embodiment of the axle-positioning member of the present bendable/twistable rolling conveyor guide, illustrating a bi-directional, non-chamfered axle design;

FIG. 11 is a perspective view of another preferred embodiment of the axle-positioning member of the present bendable/twistable rolling conveyor guide, illustrating a unidirectional, non-chamfered axle design;

FIG. 12 is a perspective view of a preferred embodiment of the present bendable/twistable rolling conveyor guide disposed along a conveyor transfer;

FIG. 13 is a perspective view of another preferred embodiment of the present bendable/twistable rolling conveyor guide;

FIG. 14 is a front view of the conveyor guide of FIG. 13;

FIG. 15 is a side view of the conveyor guide of FIG. 13;

FIG. 16 is a side detail view of the lower portion of the conveyor guide of FIG. 13;

FIG. 17 is a perspective view of another preferred embodiment of the present bendable/twistable rolling conveyor guide

FIG. 18 is a perspective view of another preferred embodiment of the present bendable/twistable rolling conveyor guide;

FIG. 19 is a front view of the conveyor guide of FIG. 18;

FIG. 20 is a side view of the conveyor guide of FIG. 18;

FIG. 21 is a side detail view of the lower portion of the conveyor guide of FIG. 18;

FIG. 22 is a raised side perspective view of a conveyor assembly including a plurality of twisted rolling conveyor guides having properties of the preferred embodiments described herein;

FIG. 23 is a cross-sectional end view of the conveyor assembly of FIG. 22, taken along the line 23—23 in FIG. 22;

FIG. 24 is a cross-sectional end view of the conveyor assembly of FIG. 22, taken along the line 24—24 in FIG. 22;

FIG. 25 is a cross-sectional end view of the conveyor assembly of FIG. 22, taken along the line 25—25 in FIG. 22;

FIG. 26 is a cross-sectional end view of the conveyor assembly of FIG. 22, taken along the line 26—26 in FIG. 22;

FIG. 27 is a detail end view of the portion of the conveyor assembly of FIG. 26 outlined by the box labeled 27—27; and

FIG. 28 is a raised side perspective view of an end portion of the conveyor assembly of FIG. 22.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a fully assembled length of a preferred embodiment of the present bendable/twistable rolling conveyor guide 20. The individual components of the guide 20 are illustrated in FIGS. 2–6. The guide 20 includes an elongate structural support member 22, shown in detail in FIG. 4. This member 22 has a generally U-shaped cross-section, with two equal length extension arms 24 connected by a span 26. The support member 22 is adapted to be mounted on an appropriate surface alongside the conveyor by means of a channel 28 running along the length of the back surface 30 of the support member 22. The channel 28 is adapted to slidably engage a support surface, such as a strip of material, or a fastening member, such as a bolt head.

Each extension arm 24 preferably includes a generally U-shaped channel 32 in spaced relationship with the span 26, with the open sides of each channel 32 facing one another. Each channel 32 has oppositely disposed V-shaped grooves 34 that are adapted to slidably engage an axle-positioning member 36.

In one embodiment, the structural support member 22 is constructed of a rigid material. For example, the structural support member 22 could be constructed of a metal, such as aluminum. In another embodiment, the structural support member 22 is constructed of a flexible material. For example, the structural support member 22 could be constructed of a plastic, a polyvinylchloride (PVC), a polyamide or a polypropylene. The structural support member 22 could also be constructed of an extruded rubber. As those of skill in the art will appreciate, certain of the materials listed above are rigid, while certain others are flexible. Thus, a structural support member 22 constructed of one of these materials may be rigid or flexible. Advantageously, structural support members constructed of these twistable materials do not significantly distort when twisted about a longitudinal axis.

The axle-positioning member 36 shown in FIGS. 2, 3, 5A, 5B, 6A and 6B includes two oppositely disposed chain-like strips, each having a cross-section that is adapted to fit snugly within, and be retained by, the channel 32 of the extension arm 24. Each strip is divided into individual links 38 by uniformly spaced notches 40 along the length of the strip. Although the figures show a length of the axle-positioning member 36 having seven links, those of skill in the art will appreciate that this member 36 and the support structure 22 in which it is housed could be manufactured in any of a variety of lengths having any number of axles 42.

In a preferred embodiment, each link 38 of one strip has an integrally formed elongate axle 42 extending from the center of the surface facing the other strip, and each link 38 of the other strip has a central socket 44 adapted to receive the end of an axle 42. Each axle 42 is generally cylindrical and adapted to receive at least one rotatable element 46, such as a bead or roller. In a preferred embodiment, the ends of each axle 42 include a chamfer 48 that facilitates insertion of the axle 42 end into the socket 44 by eliminating the need for all axles 42 to align exactly with all sockets 44 at the same time. The length of each axle 42 is variable depending on the number of rotatable elements 46 that are to be installed on each one.

The rotatable element 46 on each axle 42 may stand adjacent to the rotatable element 46 on the neighboring axles 42, or they may be offset so that they interlock. FIGS. 2 and 3 illustrate the interlocked configuration. An interlocked pattern is preferred, because it minimizes many of the gaps between elements 46 that tend to trap conveyed articles as they pass. If the elements 46 are to be offset, at least every other axle 42 preferably includes one or more spacers 50 (FIG. 5B). In order to make assembly of the bendable/twistable rolling conveyor guide 20 easier, spacers 50 may be formed integrally with some or all of the links 38 of each strip. In a preferred embodiment, every other link 38 has an integrally formed spacer 50 attached to the surface facing the other strip. Depending upon the rotatable element 46 arrangement desired, spacer 50 orientation may either be opposing, as in FIG. 3, or alternating, as in FIG. 2. Also, the heights of each of the axles 42 may alternate, as in FIGS. 5B and 6B, depending on how the spacers 50 and rotatable elements 46 are to be arranged.

Those of skill in the art will appreciate that it is not necessary to mold spacers 50 integrally with the links 38. However, such integral molding facilitates assembly of the entire guide 20, reducing the overall difficulty and cost of making the guide 20. Those of skill in the art will also appreciate that it is not necessary to mold the axles 42 integrally with the spacers 50 or the links 38. For example, the axles 42 could be formed as separate cylindrical pins, each pin having opposite ends that fit into the sockets 44 in the links 38.

The axle-positioning member 36 can be made of any material suitable to withstand the anticipated loads upon the conveyor guide 20 and to have a low-friction compatibility with the rotatable elements 46, which are most often acetal, polypropylene or nylon. Metals provide greater strength than plastics, but plastics are easier to mold. Thus, if metals must be used, the economic advantages associated with integrally molding the spacers 50 and the links 38 may be lost. When acetal rotatable elements 46 are used and expected loads are relatively light, the member 36 may be manufactured from a material such as PBT which is preferred for reduced friction and structural strength.

The axles 42 may also be made of any material suitable to withstand the anticipated loads upon the conveyor guide 20 and to have a low-friction compatibility with the rotatable elements 46. If the axles 42 are to be formed integrally with the spacers 50 and the links 38, then these components are preferably molded from plastics in order to achieve the cost savings described above. However, if the axles 42 are to be formed separately from the spacers 50 and the links 38, then the axles 42 may easily and cheaply be machined from metals and inserted into the sockets 44 in the links 38 during the assembly process. Metal axles 42 may, for example, be used when the anticipated loads on the conveyor guide 20 are great.

FIGS. 7A–7C illustrate the design of the notches 40 between the links 38 of each strip. In FIG. 7A, the links 38 have square corners 52. These corners 52 interfere with the side walls 54 of the extension arm channel 32 when the entire assembly 20 is bent. The interference leads to two problems. First, it makes it difficult, if not impossible, to remove the axle-positioning members 36 from the channel 32.

Second, it places strain on the links 38 that can lead to upsetting the orientation of the axles 42. Because the rotatable members 46 are preferably in close proximity to one another, any upsetting of the axle 42 orientation can cause the rotatable members 46 to interfere with one another. This interference can compromise the ability of the guide 20 to provide a low-friction surface.

In FIG. 7B, the corners 56 have been rounded somewhat. The rounding lessens the interference somewhat, but it is still a potential problem. FIG. 7C illustrates a more preferred shape for the links 38. Links 38 of this shape largely eliminate interference with the channel 32 and greatly facilitate bending of the assembled guide 20. Theoretical radii as small as 5″ can be accomplished without undesirable distortion of the channel 32 or the axle-positioning members 36.

FIGS. 5A and 6A illustrate preferred embodiments of a first strip 37 of the axle-positioning member 36. FIGS. 5B and 6B represent preferred embodiments of a second strip 35, which mates with the first strip 37 to form the complete axle-positioning member 36. To assemble the axle-positioning members 36, the manufacturer begins with the second strip 35. Hereinafter, the second strip 35 is referred to as the lower strip 35. However, those of skill in the art will appreciate that when the guide 20 is assembled, the second strip 35 may be oriented above the first strip 37.

The second strip 35 includes integral axles 42. In the illustrated embodiment, the axles 42 have different lengths. Those of skill in the art will appreciate that the axle 42 lengths may be varied in any manner to suit a particular application. For example, they may be of uniform height, they may alternate in height, as in FIGS. 5B and 6B, or they may increase steadily in height from one end of the strip 35 to the other.

During the manufacturing process, the lower strip 35 is positioned so that the axles 42 are oriented upward. The appropriate number of rotatable elements 46 are then placed upon the axles 42. As long as the axles 42 are oriented upward, gravity holds the rotatable elements 46 in place.

Because the preferred arrangement of rotatable elements 46 is an interlocked pattern, as shown in FIGS. 2 and 3, the axles 42 preferably receive the rotatable elements 46 in a proper sequence to avoid any rotatable elements 46 blocking the passage of neighboring rotatable elements 46 as they move down the axles 42 to their resting positions. One such method is to first place one rotatable element 46 on each axle 42 having no spacer 50, and then place one rotatable element 46 on each axle 42 having a spacer 50, continuing with this pattern until all rotatable elements 46 have been installed.

Once all rotatable elements 46 have been installed, the upper strip 37 is placed atop the ends of the axles 42. To aid insertion of the axle 42 ends into the sockets 44, a preferred embodiment provides a chamfer 48 on the ends of the axles 42 and/or within the sockets 44. If a number of lengths of strips are to abut one another, the transitions between adjacent strips can be smoothed by offsetting the upper strip 37. In this way, no seam in the upper strip 37 would be directly opposite a seam in the lower strip 35. This arrangement helps to minimize gaps between axles 42.

Alternatively, the ends of each strip can be provided with mating apparatus so that they can be securely attached to one another. For example, each strip could include male and female connecting portions on opposite ends.

Once the upper strip 37 is in place, the entire assembly is inserted slidably into the channels 32 of the support member 22. If a bent length of guide 20 is desired, the assembled guide 20 is bent in a manner described below. If a twisted length of guide 20 is desired, the assembled guide 20 is twisted in a manner described below.

FIGS. 8 and 9 illustrate a preferred method of bending the assembled device 20 using a three-roll bender. Such a bending apparatus may be used to bend the assembled device 20 when the support member 22 is constructed of a rigid material that cannot be bent by hand. The bending apparatus preferably imparts to the support member 22 a permanent bend that allows the support member 22 to be incorporated into a bent section of a given conveyor system.

The bender includes an adjustable roll 58 and two stationary rolls 60. The cross-sections of each roll 58, 60 are shaped as mirror images of the surfaces of the support member 22 that each roll engages, as illustrated in FIG. 9. The adjustable roll 58 thus includes a center flange 62 to fit between the legs of the channel 28 on the back surface 30 of the support member 22, and upper 64 and lower 66 tapered sections to match the corresponding tapered sections on the back surface 30 of the support member 22. The stationary roll 60 includes upper 68 and lower 70 V-shaped surfaces to engage the corresponding upper 72 and lower 74 V-shaped surfaces on the front surface of the support member 22. The V-shaped surfaces on the front surface of the support member 22 are illustrated in detail in FIG. 4C.

These unique cross-sections on both the support member 22 and the bending rolls 68, 70 facilitate bending of the guide 20. A common problem when bending rolling guides is distortion of the channel 32 in which the axle-positioning member 36 fits. Such distortion can cause axle 42 misalignment and the problems associated therewith. The V-shaped surfaces 72, 74 on the exterior of the channel 32 together with the corresponding V-shaped surfaces 68, 70 of the roller 60 largely eliminate channel 32 distortion. The axles 42 thus remain aligned within the bent guide 20. Of course, as will be understood by those of skill in the art, the surfaces 72, 74 on the member 22 may be of any configuration to align with the surfaces 68, 70 of the roller 60 to facilitate predictable and uniform bending.

The design of the rolling guide 20 makes bending so easy that it may be performed by the guide 20 purchaser. Three-roll benders of the type used to bend these guides 20 are inexpensive to purchase or rent, and require little expertise to use properly. Thus, the guides 20 can be manufactured in standard straight lengths, keeping costs low, and bent by the purchaser to suit a particular application. Alternatively, the purchaser can request the guides 20 to be bent by the manufacturer prior to delivery. Because the guides 20 are so easy to bend, bending by the manufacturer does not significantly raise the cost of the guides 20.

FIGS. 8 and 9 illustrate the proper configuration to form an interior bend. Most curved conveyor sections require a guide on both the interior and exterior side of the curve. Thus, to form an exterior bend, the adjustable roll 58 in FIG. 8 is exchanged for one having the same cross-section as the stationary roll 60 in FIG. 8, and vice versa. The assembled guide 20 is passed through the rolls 58, 60 in the opposite orientation as in FIG. 8, so that the rotatable element 46 surface faces the new adjustable roll 58.

In certain embodiments, the support member 22 may be constructed of a material that is flexible, or that is rigid but capable of being bent by hand (without the need for a bending machine). For example, many extruded plastics, such as extruded PVC, have such bending properties. When constructed of certain materials, the support member 22 is also capable of being twisted, in addition to being bent. Extruded PVC is one material that enables the support member 22 to be twisted and bent. Additional examples of such materials are polyamides, polypropylenes and extruded rubbers.

FIGS. 10 and 11 illustrate two alternate embodiments of the axle-positioning members 36 of the present bendable/twistable rolling conveyor guide 20. In FIG. 10, the strips of the axle-positioning member 36 are formed such that every other link 38 has an integral axle 42. In FIG. 11, the ends of the axles 42 are formed without a chamfer.

FIG. 12 illustrates the conveyor guide 20 disposed in a transfer operation. Conveyed articles typically need to be transferred from one conveyor to another as they travel through an industrial installation. Rolling conveyor guides, such as the one disclosed here, are typically needed in these areas to prevent problems such as jamming or tipping of articles.

FIGS. 13–21 illustrate alternate preferred embodiments of the present bendable/twistable rolling conveyor guide 80, 82, 104. These guides 80, 82, 104 include channels having a different cross-sectional shape from the guide 20 illustrated in FIGS. 1–12. As FIGS. 15, 16, 20 and 21 illustrate in detail, inner walls of the channels 84 include V-shaped surfaces, with the V's opening in opposite directions. A vertical cross-section of each channel 84 thus resembles an hourglass. A vertical cross-section of each axle-positioning member strip 86 is similarly shaped like an hourglass, such that the strips 86 fit snugly within the channels 84 in a mating engagement. The strips 86 are preferably slidable along the channels 84, as described above with respect to the guide 20.

With continued reference to the end views of FIGS. 15, 16, 20 and 21, an outward facing wall 88 of each channel 84 is V-shaped, with each V opening away from the interior of the channel 84. These outward facing walls 88 are adapted to engage and mate with complementary surfaces of a bending device, such as a three-roll bender. The guides 80, 82, 104 are thus easily bent as described above with respect to the guide 20. Complementary engagement of the outward facing walls 88 and the surfaces of the bending device enables the guides 80, 82, 104 to be bent without distortion of the channels 84. The guides 80, 82, 104 thus provide the same cost savings and other benefits of the guide 20 described above.

With reference to FIGS. 13, 17 and 18, the guides 80, 82, 104 preferably include two pairs of vertically spaced channels 84 divided by a central wall 85. Each pair of channels 84 is adapted to receive axle positioning members, such that each guide 80, 82, 104 includes oppositely facing rotatable members 90. The guides 80, 82, 104 are thus adapted to be placed in between neighboring conveyors. In FIGS. 13 and 17 the rotatable members 90 comprise beads, while in FIG. 18 the rotatable members 90 comprise rollers.

An upper portion 92, 94 of each guide 80, 82, 104 includes apparatus that enables the guides 80, 82, 104 to be mounted between neighboring conveyors. The guide 80 (FIG. 13) includes an upwardly extending wall 96 that is an extension of the dividing wall 85. The upwardly extending portion 96 is adapted to engage mounting hardware, such as bolts, that secure the guide 80 in place relative to a conveyor.

The guides 82, 104 (FIGS. 17–21) include a channel 98 having an open slot 99 in an upper wall. A width of the slot 99 is less than an overall width of the channel 98, thus creating overhanging flanges 101 on either side of the slot 99. The flanges 101 are adapted to engage mounting hardware, such as a flat strip, or bolt heads, that secure the guides 82, 104 in place relative to a conveyor. Those of skill in the art will appreciate that the mounting apparatus 96, 98 could be located on the lower portions 100, 102 of the guides 80, 82, 104 rather than, or in addition to, the upper portions 92, 94.

FIG. 22 illustrates an example of a conveyor assembly 200 that incorporates a plurality of twisted rolling conveyor guides 202. With reference to FIGS. 23–26, the illustrated assembly 200 includes four guides 202. Each guide 202 traces a helical path about a longitudinal axis L of the assembly 200 (FIG. 22). To produce this helical path, each guide 202 is twisted about its respective longitudinal axis while opposite ends of each guide 202 are displaced relative to one another along axes X, Y that are perpendicular to the longitudinal axis of the assembly 200 (FIG. 22).

Those of skill in the art will appreciate that the assembly 200 of FIG. 22 may be just a component of a larger conveyor system. Accordingly, while the illustrated assembly 200 includes four guides 202 that surround the conveyed articles 204, the portions of the overall system at either end of the illustrated assembly 200 may include more or fewer guides 202. For example, articles 204 entering the illustrated assembly 200 may be moving on a powered belt that has guides 202 on either side, but no guide 202 above. Similarly, articles 204 exiting the illustrated assembly 200 may land on a powered belt, or a packaging pallet, for example.

Articles 204 passing through the illustrated assembly 200 may be driven by gravity. For example, an exit end 206 of the assembly 200 may be lower than an entrance end 208 thereof. Or, if the path from the entrance end 208 to the exit end 206 is flat, articles 204 may simply slide along the assembly 200 under the momentum that they bring with them upon entering the assembly 200. Although the articles 204 as illustrated are spaced out, articles 204 may, for example, be driven through the illustrated assembly 200 by being pushed from behind by other articles 204. A powered conveying means (not shown), such as a V-belt or a cable, may push the articles 204 through the assembly 200.

With reference to FIG. 27, each guide 202 is similar to the guide 20 described above. The guide 202 includes an elongate structural support member 210 that is shaped substantially as a U, including two equal length extension arms 212 connected by a span 214. The guide 202 farther includes first and second axle-positioning members 216 slidably disposed within spaced channels 218 in the extension arms 212. A plurality of axles (not shown) extends between the axle-positioning members 216, and at least one rotatable element 220 is positioned upon each axle. Those of skill in the art will appreciate that the rotatable elements 220 could be fixed (that is, not rotatable) with respect to the axles.

As in the guide 20 above, the guide 202 illustrated in FIG. 27 includes a channel 222 running along the length of the back surface thereof. The channel 222 is adapted to slidably receive a support member that positions the guide 202 in a desired configuration. With reference to FIGS. 23–28, in the illustrated embodiment the channel 222 on each guide 202 receives an end portion 224 of a fastening member 226. This end portion 224 may simply be a bolt head. The bolt head may be an ordinary hexagon-shaped head, or a specialized wide head. Rather than fastening members 226, the channel 222 may receive a strip (not shown) of flat bar shaped material that runs along the guide 202.

With reference to FIGS. 23–26 and 28, in the illustrated embodiment a mounting bracket 228 positions each fastening member 226. The brackets 228 and fastening members 226 define a plurality of support points that help to fix the position and orientation of each guide 202. In the illustrated embodiment, each mounting bracket 228 includes an upper portion 230 and a lower portion 232. Those of skill in the art will appreciate that the mounting bracket 228 need not include upper and lower portions 230, 232. The illustrated configuration for the mounting brackets 228 is merely an example. Other shapes and supports may be used.

The upper portion 230 is a substantially rectangular member that resembles a thin-walled strip that has been bent at ninety-degrees in four places to form a rectangle. Those of skill in the art will appreciate that the upper portion 230 could be formed by any of a number of different processes, of which the foregoing is just one. Those of skill in the art will further appreciate that the upper portion 230 could have a variety of other shapes besides rectangular. For example, the upper portion 230 could be round, triangular or hexagonal. The illustrated rectangular shape is just one shape that is well adapted for conveying substantially rectangular articles, such as the articles 204 depicted in FIGS. 22–26 and 28. Depending upon the articles to be conveyed, other shapes and configurations of the brackets 228 could be used.

With reference to FIGS. 23–28, each straight wall section of the upper portion 230 includes a hole (not shown) that receives one of the fastening members 226. As described above, and with reference to FIG. 27, a first end 224 of each fastening member is received in the channel portion 222 of a guide 202. A second end 234 of each fastening member 226 passes through one of the holes in one of the upper portions 230 and receives a securing member, such as a nut 236. The fastening members 226 thus secure the guides 202 to the upper portions 230. A spacer 238 may be positioned between each guide 202 and an inner wall surface of each upper portion 230. The spacer 238 may simply be a thick washer, or any other suitable device. The spacer 238 may be constructed of a metal, or a plastic or a rubberized material that absorbs vibrations. Those of skill in the art will appreciate that the spacers 238 need not be provided. Those of skill in the art will further appreciate that alternative fastening and securing members, besides bolts and nuts, may readily be used. Those of skill in the art will further appreciate that alternative methods of attaching the guides 202 to the upper portions 230 may be used. For example, the guides 202 may be welded or adhered to the upper portions 230. The guides 202 and upper portions 230 could also be formed as a unitary whole.

With reference to FIG. 28, in the illustrated embodiment, each lower portion 232 is a substantially U-shaped member with a base portion 240 and spaced arm portions 242 extending from opposite ends of the base portion 240. However, those of skill in the art will appreciate that the configuration of each lower portion 232 may vary according to the desired orientation of the upper portion 230, and may vary according to the shape of the upper portion 230. Each lower portion 232 resembles a thin-walled strip that has been bent at ninety-degrees in two places to form a U. As FIGS. 23–26 illustrate, the lengths of the arms 242 of each lower portion 232 may vary, and the arms 242 of any given lower portion 232 may have unequal lengths.

With reference to FIG. 23, each upper portion 230 rests atop the upper ends 244 of the arms of each lower portion 232. The junctions between each upper portion 230 and the upper ends 244 upon which it rests may be secured by any practical means, such as welds, adhesive or fasteners such as brackets and/or bolts. Each upper portion 230 may reside at any angular orientation relative to the lower portion 232 upon which it rests. For example, in FIG. 23 a first side 246 of the upper portion 230 is parallel to the base portion 240 of the lower portion 232. In FIGS. 24–26, the first side 246 forms an angle a with the base portion 240. In FIG. 24, α is approximately equal to 30°. In FIG. 25, α is approximately equal to 60°. In FIG. 26, α is approximately equal to 90°.

An article 204 moving on the conveyor assembly 200 of FIG. 22 rotates 90° as it moves from the first end 208 of the assembly 200 to a second end 206 thereof. The helical path traced by each guide 202 smoothly transitions each article 204 along the twisting path without any bumps or seams along the way that could cause articles 204 to jam. The ability to rotate articles 204 as they pass is very advantageous in many conveying scenarios. For example, many articles 204 receive labeling that is printed as the article 204 passes. To place the labels on sides of the articles 204, the article 204 is preferably twisted so that the printing surface faces up. Many other articles 204 are preferably placed on their sides prior to entering a secondary packaging area. Without the benefit of the helical path provided by the present twisted guides 202, many of these articles 204 would have to be placed on their sides by hand, which is time-consuming and expensive.

As discussed above, the twistable embodiments of the present guides 202 are preferably capable of being twisted by hand, without the need for any bending or twisting machines. Accordingly, the support member 210 need not include any specialized surface features that enable the support member 210 to engage a bending or twisting machine. Furthermore, embodiments that are twistable may be bent, rather than twisted. Therefore, these embodiments may also be bent without use of bending machines, and consequently need not include any specialized surface features that enable the support member 210 to engage a bending machine. With these embodiments, it is the bendable/twistable properties of the materials, rather than the mating engagement of surface features, that contribute to the bending and twisting.

One method of constructing a conveyor assembly 200 such as the one illustrated in FIG. 22 is to first mount a plurality of mounting brackets 228 along a selected support surface (not shown). As illustrated in FIG. 28, fastening members 248, such as bolts, may pass through holes (not shown) in the base portions 240 of the lower portions 232 to secure the mounting brackets 228 to the support surface. Alternatively, the base portions 240 may be secured to the support surface by any appropriate means, such as welding or adhering. The support surface may be, for example, a floor or an elevated platform. The support surface may be flat, or it may be slanted or undulating.

Once the mounting brackets 228 are properly positioned and secured, the fastening members 226 are mounted to the upper portions 230 of the mounting brackets 228. Of course, the fastening members 226 could be mounted to the upper portions 230 before the mounting brackets 228 are properly positioned and secured. The fastening members 226 form a path along which each guide 202 may be threaded. For example, a first guide 202 may be positioned such that a first end thereof is adjacent a fastening member 226. The guide 202 may then be advanced such that the fastening member 226 enters the first end of the channel 222 in the guide 202. After advancing the guide 202 farther, such that the fastening member 226 slides through the channel 222, the guide 202 first end reaches a fastening member 226 on the next mounting bracket 228. In the illustrated embodiment, this next fastening member 226 is oriented at a 30° angular offset from the first fastening member 226, the angular offset being measured with respect to a longitudinal axis L of the conveyor assembly 200. Those of skill in the art will appreciate that consecutive fastening members 226 along a conveyor assembly 200 could be oriented at any angular offset relative to one another.

Advancing the guide 202 still farther, the guide 202 first end consecutively reaches fastening members 226 on adjacent mounting brackets 228. Each consecutive fastening member 226 is oriented at a particular angle relative to the previous fastening member 226. Thus, as the guide 202 advances, it traces the helical path described above. Eventually, the entire guide 202 is mounted along a helical path supported by a plurality of mounting brackets 228.

The configuration of the axle-positioning members 216 contributes to the twistability of the guide 202. As the guide 202 twists along its longitudinal axis, adjacent links in the chain of each axle-positioning member 216 twist with respect to one another. The notches between adjacent links enable this twisting motion without causing distortion of the axle-positioning member 216, which could cause misalignment of axles as described above with respect to bending. The twistability of the axle-positioning members 216 maintains the axles in parallel alignment, thereby creating a smooth pathway for conveyed articles 204.

SCOPE OF THE INVENTION

The above presents a description of the best mode contemplated for carrying out the present bendable/twistable rolling conveyor guide, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this conveyor guide. This conveyor guide is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this conveyor guide to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the conveyor guide as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the conveyor guide. 

1. An apparatus for guiding articles moving on a conveyor, comprising: a support structure including first and second spaced channels; an elongated first axle-positioning member slidably engaging the first channel; an elongated second axle-positioning member slidably engaging the second channel; at least one axle extending between the first axle-positioning member and the second axle-positioning member; and at least one rotatable element on the at least one axle; wherein the support structure is constructed of a material that it is adapted to allow the support structure to be twisted about a longitudinal axis thereof without causing significant distortion of the spaced channels, and wherein the first and second axle-positioning members are each configured as a chain, including a plurality of links joined to one another by notched sections.
 2. The apparatus of claim 1, wherein the support structure is constructed of plastic, or extruded plastic, or PVC, or extruded PVC, or polyamide, or extruded polyamide, or polypropylene, or extruded polypropylene, or extruded rubber.
 3. The apparatus of claim 1, wherein the support structure further comprises a third channel that is adapted to slidably receive apparatus for mounting and positioning the support structure.
 4. A rolling conveyor assembly, comprising: at least a first, a second, a third and a fourth guide member, each guide member including a support structure, a plurality of axles secured within the support structure, and at least one rotatable element on each axle; wherein the guide members are located at intervals around a longitudinal axis of the conveyor assembly, and the first and second guide members are oriented such that the at least one rotatable element on the first guide member generally faces the at least one rotatable element on the second guide member, and the third and fourth guide members are oriented such that the at least one rotatable element on the third guide member generally faces the at least one rotatable element on the fourth guide member.
 5. The rolling conveyor assembly of claim 4, wherein each guide member traces a substantially helical path from a first point of the conveyor assembly to a second point thereof. 